Fabric Softener Active Composition Using Non-Flammable Solvents
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Solution Overview
Problem
Current fabric softener active compositions face challenges in achieving high softening performance, hydrolysis stability, suitable handling and processing, good odor, and compatibility with other components, while also requiring fewer processing steps and minimizing the use of volatile solvents.
Innovation Solution
A fabric softener active composition comprising a combination of quaternary mono-, di-, or tri-ester ammonium compounds, fatty acid esters, fatty acids, and optionally fatty alcohols, with specific ranges for each component to enhance softening performance and stability, and a method involving esterification and quaternization steps to produce these compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If volatile solvents such as ethanol or isopropanol are added to quaternary ester ammonium compounds to reduce viscosity and improve handling, then the composition becomes easier to process, but the flash point decreases to less than 60°C requiring special safety measures
Solution Approach 1:
The patent removes volatile flammable solvents from the composition entirely, replacing them with non-flammable alternatives. This extracts the harmful volatile component while maintaining the necessary solvent function through non-flammable esters and alcohols, thus improving safety without sacrificing handling properties
Solution Approach 2:
The patent changes the physical-chemical parameters of the solvent system by substituting volatile solvents with non-volatile or low-volatility esters and alcohols. This parameter change increases the flash point from below 60°C to above 60°C while maintaining adequate viscosity reduction and handling characteristics
2Reliability
If quaternary ester ammonium compounds are used in solid state, then softening performance is high, but handling and processing becomes difficult due to lumping and high viscosity at low melt temperatures
Solution Approach 1:
The patent introduces non-flammable esters and alcohols as intermediary substances that facilitate handling of the quaternary ester ammonium compounds. These intermediaries reduce viscosity and prevent lumping during processing, enabling easy application while maintaining the active compound's softening performance
Solution Approach 2:
The patent creates a composite system combining quaternary ester ammonium compounds with non-flammable esters and alcohols. This composite material integrates the high softening performance of the esterquat with the handling benefits of the ester/alcohol mixture, achieving both performance and processability
3Productivity
If flammable solvents are used to achieve low viscosity, then processing is easier, but regulatory restrictions and safety measures increase complexity
Solution Approach 1:
The patent extracts flammable solvents from the formulation, eliminating the need for special safety infrastructure and regulatory compliance measures. This removal of harmful substances simplifies the overall system complexity while maintaining processing efficiency through non-flammable alternatives
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves high softening performance, stability, and compatibility with other components, while reducing the need for volatile solvents and simplifying the processing steps, resulting in improved fabric softening properties and safety.
Implementation Method 1
Quaternary ester ammonium compounds, commonly referred to as esterquats, have found broad use as fabric softener actives due to their high softening performance
Implementation Method 2
The solvent function is to improve the quaternary ester ammonium compounds handling and processing (viscosity reduction in fabric softener active compositions and/or water dispersibility increase from the molten state)
Data Source
AI summary
The present invention relates to fabric softener active compositions comprising a combination of a quaternary ester ammonium compound and fatty solvents (a fatty acid ester, a fatty acid, a fatty alcohol and mixtures thereof) and methods of making and using the same. The invention also proposes fabric softener compositions, comprising the previously described active compositions, and methods of making and using the same.